Protective material for molds and method of forming the same



, Patented May 8, 1923'.

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To all whom it may concern: Be it known that we, Hmsnn'r A. MYERS andARTEEMES D. STRAW, citizens of the United States, andresidents ofToledo, Lucas 5 County, Ohio, and Wauseon, Fulton County, Ohio, havemade an Invention Appertaining to Protective Material for Molds andMethods of Forming the Same; and we do hereby declare th following to bea full,-

clear, and exact description of the invention,

such as will enable others skilled in the art to which it appertainstomake and use the same. r i

The purpose of our invention is to provide a protective material forarticles of different kinds used in handling or manipulating hot moltenmaterial. It particularly has for its object to enable'the rapidproduction of castings of metals having. relatively high melting pointsin permanent molds, especially the formation of ferrous metal castingsin' iron molds. The protective materials embodying our invention mayform alloys or mixtures within the articles with which they are used,and at the same time produce coatings on the articles that will formhard smooth surfaces. The protective 'materials or portions thereof mayhav an affinity for and form alloys or mixtures with the material ormaterials of the articles to which they are applied, which will'produceexceedingly durable surfacing materials that will withstand a largenumber of applications of-the heated metal without deterio-t ration ofthe surfacing materials, and without injury to the article. In case ofmolds 1t will permit the rapid and continuous for nation of smooth,substantially perfect castmgs. 3 .a The composition ofmaterials utilizedwill fill-the pores of the mold, particularly of iron molds, and willform a coatinghaving a hard, compact, smooth surface that will resisterosion and will prevent pitting and blistering of the casting andpitting .01"

segregation of the materials of which the 'mold is composed.

Th alloying material slightly penetrates the molding surface and thecoating pro duced is an exceedingly thin layer, about one-hundredth ofan inch thick. The alloy and coatin may be formed or built up in the useof the article by frequent applications of a-suitable material orsuitable mate- .parts'of the mold to be protected from the face ofthe-mold and a hard coating of iron,

mold contains, not considerin Application filed mum 30,1922. Serial no.532,569.,

rials between the applications of the molten metalto the article, suchas, in the case of a mold, between casting operations, utilizing theheat and the pressure of the molten metal that form the castings to heatcompress and perfect the mixture and "produce its final protectivecondition, or the protective material may be applied in any manner andwith the use of heat and pressure such as the heat and pressureproducedby the molten metal of one or more castings.

The protective material embodying our invention contains a metal havinga low vaporizing or boiling point, thatis, broadly, a low gasifyingpoint, such as zinc, zinc chloride, cadmium, barium, or bismuth,"acarbonaceous material and iron, from which may be formed, "first, alloysof mixtures of the metal with the iron'and' the-carbon within thesurface of the article, and, secondly, coatings that contain mixtures ofthe oxide of the metal selected, carbon and iron, and a small amount ofthe metal thatmay alloy with th iron. The proportions of the ingredientsof the materials; may be varied according to the'comp'osition of themold, the metal or alloy'that is tob cast therein, and the physical andchemical characteristics to be produced in the casting. Particularlyadvantageous re'sultsare obtained when the protective material contains'zinc'a'nd is deposited on iron articles,since zinc is {readily formedfrom its compounds and will adhere to or alloy with the ironand in thepresence of air readily forms a coating containing zinc oxide on thesurface ofthe articles. To cast ferrous metals in ferrous molds we findi't-preferable to place a layer containing zinc oxide and carbon overthe molten metal and to utilize the iron of the 95 mold or of thecasting, or both, to produce. an alloy or mixture containing iron, zincand carbon that'is formed within the sur-- zinc oxide and carbon on thesurface of the mold. The alloy or mixture that penetrates or is formedWithin the surface of the mold and the coating on the mold maycontainthese ingredients in various proportions. The alloy or mixture within"the surface of the impurities, about 3% to 5% of carbon, a out 50% to60% of iron, and about 30% to 40% of zinc,

as f

and a small amount of zinc oxide. A sample mixture runs'about 4% ofcarbon, 50% of iron, 44% of zinc and a small amount of zinc oxide. Thecoating mixture contains about 5% to. 15% of carbon, 8% to 14% of iron,and the balance of zinc oxide, with a small amount of'zinc, ordinarilyabout 8% of carbon, 12% of iron, of zinc oxide, and the balance of zinc.The amount of the zinc varies, it being probably located at the point ofunion between the coating and the.

mold and indistinguishabl between the coating and the alloy in the mold.It possibly forms a sub-layer between the two and concoated, as justdescribed, or it maybe my other suitable metal havmg vaporizing andboiling'points lower than that of the metal to be cast in the mold, andpreferably one having an oxidizing oint in -atmospheric oxygen below themelting point of the metal to be cast. A layer of carbonaceous material,such as the products of an incomplete combustion flame produced from ahydrocarbon fluid fuel, such as acetylene or ordi- 118.13 fuel gas orcarbureted gasolene or oil,; is e posited over the oxide. The mold isthen filled with the molten metal from which the castings are to beformed. After the removal of the casting a succeeding layer of the metaloxide and carbon is again formed over the matrix and another casting ismade. Upon removal of the casting another layer of the metallic oxideand a'layer of carbon is formed, and so on repeatedly until theprotective material is suiiiciently built up on and formed in the mold.This is accomplished ordinarily after ten or twelve castings have beenmade in the mold.

In forming the protective material, deposits of carbonaceous materialsmay be omitted. If desired, layers of any wellknown heat insulatingmaterial, such as magnesia, may be deposited over the layers of metallicoxide, between each of thecastings in the preparation of the mold. Alsothe preparatory dipping or impregnation may be omitted, since the oxidemay be reduced by the iron. or carbon or a reducing flame, and the metalthus released from its oxy en will alloy with or penetrate the mold.

T e deposition of the protective material on the mold may beaccomplished in various ways, such as spraying the metal or one ofmarinas its oxides or saltson the mold. Also the material may bedeposited by painting and, if need. be, mixtures with vehicles may beused. If desired, the mold'may be heated during the application of themetal. Also the metal or its, oxide or its salt may be deposited in amixture of carbonaceous material on the mold in any suitable way, suchas painting or spraying or dipping. The

.oxide, if used, may be subsequently reduced by heating the mold eitherby a suitable heater or by casting molten metal in the mold and thedesired alloy or mixtures formed at or within the surface of the mold.

Also the preparatory impregnation of the mold may be accomplished byinserting the mold in a container of metal gas or directin as of themetal against the mold. If this is done in the presence of oxygen, oxideof the metal will be deposited. The amount of the oxide thus producedwill vary according to the amount of concentration of the oxygen.

Inasmuch as the protective substances prevent adherence of metal tometal and to aluminous and cementitious materials, the protectivecomposition may be formed on or incorporated in ladles, pots, troughs,or other articles formed of metal or of the said materials, orboth, andused in handling or manipulating molten iron.

The term mixture as used in the claims, covers broadly both alloys andmixtures.

We claim:

1. A container having metalincorporated therein and for containingmolten metals,

and having a protective coating comprising carbon, iron, and an oxide ofa metal gasifiable below the melting point of iron.

2. A container having metal incorporated therein and for containingmolten metals, and havinga protective coating comprising carbon, iron,and zinc oxide.

3. A container having metal incorporated therein and for containingmolten metals, and having a protective coating comprising from about 5%to 15% of carbon, 8% to 14% of iron, and zinc oxide.

4. A container having metal incorporated I therein and for containingmolten metals, and having a protective coating comprising about 8% ofcarbon, 12% of iron, and 75% of zinc oxide. 7

5. A container having metal incorporated therein and for containingmolten metals, and having a protective coating comprising from about 5%to 15% of carbon, 8% to 14% of iron, and an oxide of a metal, the

. gasifying point of the metal being below that of the melting point ofiron.

6. container having metal incorporated therein and for containing moltenmetals,

and having a protective coating comprising about 8% of carbon, 12% ofiron, and 75% of the oxide of a metal, the gasifying point I castings,

and 75% prising about 8 and 75% metal gasifiable below the melting pointof iron.

8. container having iron incorporated therein and for containing moltenferrous metals, and .having a protective coating com prising carbon,iron, and zinc oxide.

9. container having iron incorporated therein and for containing moltenferrous 'metals, and having a protective coating com- 5% to 15% ofcarbon, 14% of iron, and zinc oxide.

iron incorporated prising from about 8% to 10. A containrhaving thereinand for containing molten ferrous metals,

and having a protective coatin comprising. about 8% of carbon, 12% 0iron,

of zinc oxide. 11. A container having iron incorporated therein and forcontaining molten ferrous metals, and having a protective coatingcomprising from about5% to 15% of carbon, 8% to 14% of'iron, andan-oxide of a metal,

" the gasifying point of the metal being below that of themeltin pointof iron.

12. A container haying therein and for containing molten ferrous metals,and having a protective coating com.- of carbon, 12% of iron, of theoxide of a metal, the gasifying point of the metal being below that .ofthe melting point of iron. 13. A metal-containing mold for metalcastings, and having a protective coating comprising. carbon,-.iron, andan oxide of a metal gasifiable below the melting point of iron.

14. A metal-containing and having a protective coating comprisingcarbon, iron, and zinc oxide.

15. A metal-containing mold for metal castings, and having a' protectivecoating comprising from about 5% to 15% of carbon, 8%"to 14% of iron,and zinc oxide.

16. A metal-containing mold for metal.

castings, and having a protective coating comprising about 8% of carbon,12% ofiron,

and 75% of zinc oxide.

17. A metal-containing mold for metal castings, and having a protectivecoating comprising from about 5% to 15% of carbon, 8% to 14% of iron,and anfoxideof a castings,

metal, the gasifying point of themetal being below that of the meltingpoint of iron.

18. A metal-containing mold for metal and having a protective coating ofcarbon, 12% of iron, and 7 5% of the oxide of a metal, the. asifyingpoint of the metal being below t at of the melting point of iron.

19. A' mold containing iron for metal castcomprising about 8% point ofiron.

iron incorporated mold for metal metals, and having'a protective coatiuprism carbon, iron, and an oxide of a metal gasifia 1e below the meltingoint of iron.

20. A mold containing iron or metal castings, and having a protectivecoating comprising carbon, 113011, and zinc oxide. '2

' 21. A'mold containing iron for metal castcoating comings, and having aprotective prising from about 5% to 15% of carbon, 8% to 14% of iron,and zinc oxide.

22. A mold o ntaimng iron about 8% of carbon, 12% of zinc oxide. f T

23. A mold containing ironfor castings, and having a protective coatingcomprising from about 5% to 15% of carbon, 8%- to 14% of iron, and anoxide of a nietal, the

asifying'point of the metal being below t at of the melting point ofiron.

24. A -mold containing iron and having a protective coating comprisingabout 8% of carbon, 12% of iron, and 7 5% of the oxide of a metal, thegasif ing oint of the metal being below that oft e me ting 25. An ironmold metals, and having a prising carbon, iron, and an oxide of a metalgasifiable below the melting point of iron.

, 26. An iron mold for casting ferrous metals, prising carbon,

foi-

casting ferrous iron, and zinc oxide.

' 27. An iron mold for casting ferrousv and having a protective coatingcom- 5% to 15% of carbon, and zinc oxide.

metals, prising from about 8% to 14% of iron,

'ings, and having a protective coating comfor castings, and'having aprotective coating comprisin of iron, and o for castings,

protective coating comand having a protective coating com-.

28. An iron mold for casting ferrous i metals, and having a protectivecoating com prising about,8%-of carbon, 12% of iron, and 75% ofzincoxide.

29. An iron mold for' castingferrous metals, and having a protectivecoating comprising from about 5% to 15% of -carbon, 8% to 14% of iron,and an oxide of a metal,

the gasifying point-of the metal being below that of the melting pointof iron. v

' 30. An iron mold for casting ferrous com- 8% of carbon,'12% 0 iron,

prising about the oxide of a metal, the gasifyand 75% of ing point ofthe the melting point of iron.

31. A container having metal incorporated therein and for containingmolten metals,

metal being below that of and having a subsidiary protective materialcomprising carbon, iron, and zinc.

32. A container having metal incorporated therein andfor'containingmolten metalsl,

and having a subsidiary protective materia comprising from about 3% to5% of carbon 50% to 60% ,of iron, and 30% to 40% o zinc.

33." A container having metal incorporated therein and for containingmolten metals,

and a subsidiary protective material comprising about 4% of carbon, 50%of iron, and44% ofzinc.

34. A container-having metal incorporated therein and for containingmolten metals, and having a subsidiary protective material comprisingfrom about 3%'to5% of carbon, 50% to 60% of'iron, and a metal having agasifying point below that of the melting point of iron.

35. A container having metal incorporated therein and for-containingmolten metals, and having a subsidiary protective material comprising 4%of carbon, 50% of iron, and 44% of a metal having a gasifying pointbelowthat of the melting point of iron.

36. A metal containing mold for metal castings, and having a subsidiaryprotective material comprising from about 3% to 5% of carbon, 50% to 60%of iron, and 30% to 40% of zinc.

37. A metal containing mold for metal castings, and having a subsidiaryprotective material comprising about 4% of carbon,

50% of iron, and 44% of zinc.

38. A metal containing mold for metal castings, and having a subsidiaryprotective material comprising from about 3% to 5% of carbon, 50% to 60%of iron, and a metal having a gasifying point below that of the meltingpoint. of iron.

A metal containing mold for metal castings, and having a subsidiaryprotective material comprising about 4% of carbon,

" 50% of iron, and 44% of a metal having a gasifying point below that ofthe melting point of iron.

40. A mold containing iron for metal castings, and having a subsidiaryprotective material comprising carbon, iron, and a metal gasifiablebelow the melting pointv of iron.

41. A mold containing iron for metal castings, and having a subsidiaryprotective material comprising carbon, iron, and zinc.

42. A mold containing iron for metal castings, and having a subsidiaryprotective material comprising from about 3% to 5% of carbon, 50% to 60%of iron, and 30% to 40% of zinc.

43.-A mold containing iron for castings, and having a subsidiaryprotective material comprising about 4% of carbon, 50% of iron, and 44%of zinc.

44. A mold containing iron for castings, and having a subsidiaryprotective material comprising from about 3% to 5% of carbon, 50% to 60%of iron, and a metal having a gasiiying point below that of the melt ingpoint of iron. i

45. A mold containing iron for castings, and having a subsidiaryprotective material comprising about 4% of carbon, 50% of iron, and 44%of a metal having a gasifying point below that of the melting point ofiron. Q

a gasitying inaaoee 46. A container having metal incorporated thereinand forcontaining molten metals, and having a protective mixtureincorporated within the surface of the container comprising carbon, anda metal gasifiable below the melting point of iron.

47. A container having metal incorporated therein and for containingmolten metals, and having a protective mixture incorporated within thesurface of the container comprising carbon and zinc.

48. A container having metal incorporated therein and for containingmolten metals, and havinga protective mixture incorporated Within thesurface of the container comprising from about 3% to 5% of carbon, 50%to 60% of iron, and 30% to 40% of zinc.

49. A container having metal incorporated therein and for containingmolten metals, and having a protective mixture incorporated within thesurface of the container comprising about 4% of carbon, 50% of iron, and44% of zinc 50. A container having metal incorporated therein and forcontaining molten metals, and having a protective mixture incorporatedwithin the surface of the containercomprising from about 3% to 5% ofcarbon, 50% to 60% of iron, and a metal having a gasiitying point belowthat of the melting point of iron.

51. A container having metal incorporated therein and for containingmolten metals, and having a protective mixture incorporated ivithin thesurface of the container comprising 4% of carbon, 50% of iron, and 44%of a metal having a gasifying point below that of the melting point ofiron.

52. A container having iron incorporated therein and for containingmolten ferrous metals, and having a subsidiary protective mixtureincorporated within the surface of the container comprising about 4% ofcarbon, 50% of iron, and 44% of a metal having point below that of themelting point of iron.

53. A metal-containing mold for metal castings, and having a protectivemixture incorporated within the surface of the mold comprising fromabout 3% to 5% of carbon, 50% to 60% of iron, and 30% to 40% of zinc.

54. A metal-containing mold for metal castings, and having a protectivemixture incorporated Within the surface of the mold comprising about 4%of carbon, 50% of iron, and 44% of zinc.

55. A metal-containing mold for metal castings, and having a protectivemixture incorpora-ted Within the surface of the mold comprising fromabout 3% to 5% of carbon, 50% to 60% of iron,-and a metal having agasifying point below that of the melting castings, and having aprotective mixture incorporated within the surface of the moldcomprising about 4% of carbon, 50% of iron, and 44% of a metal having agasifying point below that of the melting oint of 1-ron.

57 An iron mold for casting ferrous metals, and having a protectivemlxture incorporated within the surface of the mold comprising carbon,iron, and a metal gasifiable below the melting point of iron, and aprotective coating comprising carbon, iron and an oxide of a metalgasifiable below the meltin point of iron. 58. 11 iron mold for castinferrous metals, and having a protective mlxture incorporated within thesurface of the mold comprising carbon, iron, and zinc, and a protectivecoating comprising carbon, iron and 'zinc oxide.

59. An iron mold for casting ferrous metals and having a protectivecoating comprising from about 5% to 15% of carbon, 8% to 14% of iron andzinc oxide and a protective mixture incorporated within the surface .ofthe mold comprising from' about 3% tov 5% of carbon, 50% to 60% of ironand to 40% of zinc.

60. The process of forming a protective material for molds for castingmetals, which comprises depositing on the mold layers of the oxide'of ametal that has a gasifying point below-the melting point of the metal ofthe casting, and of a carbonaceous material, and heating and compressingthe coating materials. 7

61. The process of forming a protective material for molds for castingmetals, which comprises depositing onthe mold layers of the oxide of ametal that has a gasifyin point below the melting point of the meta ofthe casting, and the products of an incomplete combustion flame producedfrom a hydrocarbon fuel, and heating and compressin the coatingmaterials.

62. e process of forming a protective material for molds for castingmetals, which comprises depositing on the mold lafyers'of' the oxide ofzinc and. the products .0 an incomplete combustion flame produced from ahydrocarbon fuel.

q 63. The process of forming aprotective materialfor molds for castingmetals, which consists in depositing on the mold a metal gasifiable at atemperature below the melting point of the metal of the casting, anddepositing on the reviously deposited metal a layer of the oxi e of ametal that has a gasifyin point below the melting point of the meta ofthe'casting.

64. The process of forming a protective material foriron molds for,casting ferrous metals, which consists in depositing zinc on the mold,anddepositing on the mold layers of the oxide of zinc and of acarbonaceous material, and heating and compressin the coating materials.

65. he process of forming a protective material for iron molds forcasting ferrous metals, which consists in depositin zinc on the mold,and depositing on the mo (1 layers of zinc oxide, and the products of anincomplete combustion flame produced from a hydrocarbon fuel, andheating and compressing the coating materials.

66. The process of forming a protective material for iron molds forcasting ferrous metals, which consists in depositing zinc on the mold,and also depositing on the mold layers of zinc oxide, and the productsof an incomplete combustion flame produced from a hydrocarbon fuel, andcasting ferrous metals in the molds.

67. In the process of forming a protective material for iron molds forcasting ferrous metals, which consists in depositing layers of theoxidesof a metal and of a carbonaceous material on the molds. r

68. The process of forming a protective material for iron molds forcasting ferrous metals, which consists in depositing layers of theoxides of a metal and of a carbonaceous material on the molds andheating and compressing the coating materials.

69. The process of forming a' protective material for iron molds forcasting ferrous metals, which consists in depositing layers ceousmaterial on the'molds and heating and compressing the coating materialsby casting metal in the mold.

In testimony whereof, we have hereunto signed our names to this secification. I-IUBERT MYERS. .Allt'llill']MES D. STRA'W.

of the oxides of a metal and of a carbona-

